"Today it is clear to us that this was the right step: we enjoy operational savings, a cleaner work environment, and a significant contribution to pollution reduction"

Coping with environmental regulation and high operating costs is a significant challenge for many factories. An in-depth analysis of wastewater treatment processes at a plant in northern Israel revealed immense potential for improvement.

The factory faced complex challenges in its wastewater treatment system. The old system, which operated on fixed dosing, required a dosage that could handle variable flow rates and fluctuating pollutant concentrations, leading to increased chemical consumption, environmental compliance violations, and high operating costs.

The factory was presented with offers for expensive new treatment facilities and costly upgrades.

Having previously received various offers for different facilities, the factory decided to take an innovative and creative approach. Instead of embarking on a large and cumbersome project, they gave Greenfield Eco the opportunity to prove there is another way.

Thanks to creative thinking combined with years of knowledge and experience, at the end of 2023, Greenfield Eco began a simple yet smart and efficient upgrade, including connecting the plant's facility to the Greenfield Eco network for monitoring and continuous operation support from Greenfield Eco's national control center. The factory underwent a dramatic transformation—successfully reducing pollutant concentrations significantly, saving tens of percentages in chemical costs, and achieving full regulatory compliance.

The Challenge: Inefficient System and Excessive Consumption

Before the upgrade, the system at the factory operated without precise control and without flow measurement due to gravity flow in the pipes, which prevented continuous flow monitoring. Without remote control capabilities, chemical dosing (such as coagulants) was performed at a fixed rate that did not account for incoming flow. This situation created challenges:

Overconsumption and recurring violations: A lack of coordination between different chemical dosages—the base and acid worked against each other in an un-synchronized manner, creating increased sludge volume and excessive chemical use. To ensure compliance even during high flow rates, the factory was forced to set the chemical dosing to a high level at all times. Consequently, the system often operated with an excess of expensive chemicals, which spiked operating expenses including fines for violations and high chemical costs alongside higher sludge volumes.

The factory, after consulting with environmental consultant Eldad Sharoni, decided to adopt an innovative and creative approach. Instead of going for a large and cumbersome project, they gave Greenfield Eco the chance to prove things could be done differently.

"We understood immediately that expensive and cumbersome projects aren't necessary to achieve better results. We saw the immense potential within the existing system and acted accordingly. The result? Full compliance with standards, dramatic cost savings, and tens of percent reduction in chemicals" - Roi Shifron, Professional Manager at Greenfield Eco

The Solution: Professional and Efficient Upgrade of the Existing Facility Including Control, Precision, and Training

Greenfield Eco's professional team upgraded the existing facility with an innovative and continuous treatment system by:

Smart pH Control: Installation of an advanced control system with more precise pH correction capabilities.
Connection to a Flagship Service: The factory was connected to Greenfield Eco's national control room, which monitors treatment quality using cameras, PLC connection, and 24/7 alerts. This provides a continuous response, remote dosing control, and real-time alert handling. Thus, a professional accompanies the factory around the clock, not just during periodic visits, without incurring high costs.
Process Support: On-site accompaniment to adapt chemicals and processes for optimal treatment.
Flow-Based Dosing: An innovative system that accurately controls the amount of incoming chemicals (coagulants) based on the facility's influent flow. This improved the chemical process, reduced chemical dosages, and achieved excellent results in separating solids into sludge and effluent.
Professional Training: As part of the service provided, the factory's operators underwent thorough training on the operation, maintenance, and cleaning of the upgraded facility.

Industrial wastewater control system from the Greenfield Eco network

The Results: A Turnaround in Data and Savings

Dramatic Reduction in Chemical Consumption: The transition to precise dosing was immediately reflected in the data:
- Acidic Chemical: Consumption of approximately 2,600 liters in January 2024 dropped to only 742 liters in March 2024, a decrease of over 70%.
- Basic Chemical: Consumption of approximately 275 liters in January 2024 dropped to 193 liters in March 2024, a decrease of approximately 30%.

Before the upgrade: Factory wastewater

After the upgrade:

Impressive Decrease in Pollutant Concentrations (mg/L): The following graph illustrates the continuous decline in major pollutant concentrations from the project's start in late 2023 to today, and the transition to full compliance with standards: Comparison of Pollutant Concentrations (mg/L)

The story of the Cabiran factory proves that one does not always need grandiose and expensive solutions. A custom engineering solution based on deep familiarity with the plant, production processes, and wastewater treatment improves not only operational aspects and regulatory compliance but also the business's bottom line. The transition to full compliance, alongside a dramatic reduction in chemical expenses without entering into expensive and lengthy projects, demonstrates Greenfield Eco's added value as a true partner for green and economic growth.

The Cabiran story proves: Sustainability and economic savings can go hand in hand.

Want to find out if your factory can undergo such a change? Contact us now!

Follow us on Facebook - Greenfield Eco / LinkedIn - Greenfield eco

04-6829999 / Also available on WhatsApp 055-9555874